Octagonal bulk bin

ABSTRACT

An octagonal bulk bin of corrugated paperboard has opposed parallel side walls spaced a predetermined distance apart and opposed parallel end walls spaced a predetermined distance apart. The side and end walls are joined by diagonal corner panels. The diagonal corner panels are made wider than the corner panels in a conventional bin, and the side and end walls are narrower, with the corner panels and the end walls having approximately the same width, while maintaining the predetermined spacing. This configuration reduces the bulge experienced when product is loaded into the bin. In addition to the wider corner panels, or in lieu thereof, scores may be placed in at least one of the side and end panels to define a line along which controlled and predetermined buckling will take place, if buckling occurs.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to shipping and storagecontainers. More specifically, the invention relates to corrugatedpaperboard bulk bins configured to reduce sidewall bulge.

[0003] 2. Prior Art

[0004] In the bulk handling of materials, e.g., processed poultryproducts, tomato paste, meat, fresh produce, etc., containers ofrelatively large-size are commonly used to transport and store thematerial. These containers must be capable of withstanding the weight ofthe contents, which can exceed two thousand pounds, as well as the roughhandling to which they may be subjected. Further, they should be capableof being handled with mechanized equipment, which typically requires thecontainer to be placed on a pallet. In the handling of certain poultryproducts, the pallet has dimensions of 48×40 inches, and the containersare sized to closely fit on the pallet.

[0005] A bulk bin commonly used for flowable products, e.g., ground-uppoultry products, has a generally rectangular transverse cross-section,with the four corners mitered to produce an octagonal shape. This shapefits the 48×40 inch pallet typically used in the food industry. However,the resulting container has four relatively wide side walls or panelsjoined by four narrow diagonal panels. When a flowable product is loadedinto the bin, the wide panels tend to buckle or bulge outwardly in themiddle. The added package width caused by this buckling or bulgingcreates significant pallet overhang and an interference fit in warehousestorage racks and transportation trailers.

[0006] Accordingly, there is a need for a corrugated paperboard bulk binwhich is configured to have reduced sidewall bulge when loaded withproduct, and which fits a standard 48×40 inch pallet.

SUMMARY OF THE INVENTION

[0007] The present invention comprises a bulk bin which is strong anddurable, and which is configured to have less sidewall bulge thanconventional bins when loaded with product.

[0008] In particular, the bin of the invention is made of corrugatedpaperboard and has an octagonal shape with opposed pairs of parallelside and end walls and diagonal corner panels. The diagonal cornerpanels are increased in width relative to conventional octagonal bins,whereby the diagonal corner panels have the same width as the end walls,thus reducing the width of the end walls as well as the width of theside walls. This relationship more evenly distributes the load, andreduces scoreline pressure, resulting in fewer failures and reducedsidewall bulge when the bin is loaded with product, especially flowableproduct. This eliminates problems of overhang and interference inwarehouse storage racks and transportation trailers.

[0009] The bin of the invention has adequate strength to withstand theweight of the contents, and is configured so that it is capable of beingpalletized on conventional pallets so that it can be efficiently handledwith mechanized equipment. The bin can be collapsed for compact storage,and has a locking bottom flap construction that is quick and easy to setup and is durable even when subjected to rough handling. A flexibleliner or bag is generally placed in the bin when flowable materials areto be loaded into it.

[0010] In a specific example of an octagonal bulk bin incorporating theforegoing inventive feature, the width of the diagonal corner panels isincreased by approximately 25%, or from 12¼ inches to 15½ inches, andthe width of the end walls is reduced by approximately 25%, or from 20⅜inches to 15½ inches, and the width of the side walls is reduced byapproximately 20%, or from 28⅜ inches to 23½ inches. Stated differently,the bin of the invention is a slightly elongated equilateral octagon,with two of its opposed walls approximately 50% wider than the remainingwalls. The distance or spacing between the opposed end walls and betweenthe opposed side walls preferably remains the same as in a conventionaloctagonal bulk bin, whereby the bin of the invention will fit thepallets that are conventionally used. To maintain the volume the same asa conventional bin, the height of the bin of the invention may beincreased by about 5%.

[0011] Further, strategically located crease lines may be placed in thesidewalls to cause buckling to occur in predetermined positions andpatterns, further reducing the extent of bulge of the sidewalls shouldthey buckle under pressure from the contents of the bin.

[0012] The invention is applicable to octagonal bulk bins regardless ofthe type of bottom flap construction used, but in a specific example ofthe invention, opposed pairs of major and minor bottom flaps arefoldably joined along scorelines at one edge to respective pairs ofopposed side and end walls, and have opposite free edges. The lockingbottom flap construction includes cut-outs in the major flaps, and tabson the free edge of each of the minor flaps. When the flaps are foldedinwardly toward one another to close the bottom of the box, the tabsengage in the openings in the major flaps to lock the flaps in theirinwardly folded position. It should be understood that this bottom flapconstruction does not form a part of the present invention, and otherbottom closure designs can be used.

[0013] The bulk bin of the invention also may incorporate reinforcingstraps in its sidewalls. In one specific example of the invention, thesestraps are tapes incorporated into the corrugated material. They may bespaced more closely together toward the bottom of the bin, or spaceduniformly along its height.

[0014] Although the preferred embodiment is an octagonal or eight-sidedbox, it should be understood that the invention may be adapted to otherpolygonal shapes, such as a ten-sided box, for example. Additionally,all the sides could be made equal in width, or the widths of some sidescould vary plus or minus five percent from the width of other sides.Further, the box of the invention may comprise any suitable fluteconstruction, including AA, CA, BC, etc., depending upon the desiredproperties. Moreover, a moisture resistant adhesive may be used in themanufacture of the box, which may additionally be treated with asuitable commercially available moisture resistant material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing as well as other objects and advantages of theinvention will become apparent from the following detailed descriptionwhen considered in conjunction with the accompanying drawings, whereinlike reference characters designate like parts throughout the severalviews, and wherein:

[0016]FIG. 1 is a top perspective view of a conventional octagonal bulkbin, shown on a pallet, and without any cover or liner bag;

[0017]FIG. 2 is a top perspective view of the bulk bin of the invention;

[0018]FIG. 3 is a schematic top plan view of a conventional bulk bin,showing the relatively wide side and end walls and narrow diagonalcorner panels;

[0019]FIG. 4 is a schematic top plan view of the bin of the invention,showing the substantially equal width of the end walls and diagonalcorner panels and the reduced width of the side walls, and depicting inexaggerated scale in broken lines the smaller extent of bulge of theside walls that may occur in the invention;

[0020]FIG. 5 is a plan view of the blank used in forming the bulk bin ofFIG. 2, showing reinforcing straps and strategically placed scores tocontrol buckling of the side walls;

[0021]FIG. 6 is a plan view of the blank glued up and folded flat forstorage and shipment;

[0022] FIGS. 7-9 are plan views of blanks used to form the bin of theinvention, showing different score patterns that may be placed in theside walls to control buckling and reduce bulge;

[0023]FIG. 10 is an enlarged fragmentary view in elevation of a sidewall of that form of the invention shown in FIG. 7; and

[0024]FIG. 11 is an enlarged fragmentary plan view of a side wall,showing how one of the scoreline patterns is constructed, using anelliptical shape and diagonal lines.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Referring more specifically to the drawings, a conventional bulkbin of octagonal configuration is indicated generally at 10 in FIGS. 1and 3. This bin has two opposed end walls 11 and 12, and two opposedside walls 13 and 14, joined by diagonal corner panels 15, 16, 17 and18. The bin is shown with an open top 20, and resting on a pallet 21.The side walls have a width “a”, the end walls have a width “b”, and thediagonal corner panels have a width “c”. In a typical construction, thedimension “a” is 28⅜ inches, the dimension “b” is 20⅜ inches, and thedimension “c” is 12¼ inches.

[0026] In the bin of the invention, indicated generally at 10′ in FIGS.2, 4, 5 and 6, the width “c′” of the diagonal panels 15′, 16′, 17′ and18′ is increased, and the widths “a′” and “b′” of the side and end walls13′, 14′ and 11′, 12′, respectively, is decreased relative to their sizein a conventional bin, with the same spacing between opposed side andend walls. In this regard, the dimension “c′” is increased approximately25% and the dimension “b′” is decreased approximately 25%, while thedimension “a′” is decreased approximately 20%. This results in aslightly elongated generally equilateral octagonal bin which has sixsides of equal width and two sides that are approximately 50% wider thanthe other sides, and in which the spacing between the side walls and thespacing between the end walls remains the same as in a conventional bin,whereby the bin of the invention fits on a conventional 48×40 inchpallet.

[0027] The dimensional relationship of the diagonal corner panels andthe side and end walls in the bin of the invention reduces the perimeterof the bin while maintaining the predetermining spacing between theopposed side walls and the opposed end walls, and reduces package bulgeand overhang, thus eliminating interference and fit problems onwarehouse racks and in transportation trailers.

[0028] A folded and glued blank is shown at 10′ in FIG. 6, in flattenedcondition for storage and shipment. To glue the blank, a glue tab orflap 19 or 19′ may be provided at one, end (see FIGS. 5 and 7), or apanel may be cut in half and slightly elongated to overlap, as shown inFIGS. 6 and 7. The blank is folded upon itself and the glue tabadhesively secured to a panel at the other end of the blank. The bin istypically manufactured and shipped in the condition shown in FIG. 6, anderected by the end user. To erect the bin, it is simply opened up orexpanded into a tubular configuration and the bottom flaps moved intointerlocking relationship. It may then be placed on a pallet, a baginserted into the bin, and product loaded into the bag. A cover (notshown) may be placed on the bin.

[0029] To control buckling of the side walls, and to further minimizebulging, scores may be placed in the side walls at predeterminedlocations to cause predictable and controlled buckling at certainlocations, thereby preventing buckling in the middle of a panel. Bystrategically placing the scores, buckling, if it occurs, will bedistributed in spaced locations toward the sides of the panel andprotrusion or bulge of the panel will be minimized.

[0030] A first embodiment of a buckle-controlling score is indicatedgenerally at 25 in FIGS. 5, 6 and 8. In this embodiment, the score has agenerally parabolic shape, comprising two inwardly converging diagonalscorelines 26 and 27 extending downwardly from opposite upper corners ofa sidewall panel, and connected at their lower ends by a curvedscoreline 28 spaced slightly above the midpoint of the panel.

[0031] The size and angular relationships of the scorelines aredetermined as shown in FIG. 11. Thus, in constructing the score 25, apair of imaginary diagonal lines 30 and 31 are drawn between oppositecorners of a panel, and an ellipse 32 having a length dimension “x” thatis one-third the width of the panel and a height dimension “y” that isone-sixth the width of the panel is positioned to touch the diagonals.The lower side 33 of the ellipse forms a bight that joins the twodiagonals, and the cardboard is scored along these lines to form thescore as shown, for example, in FIGS. 5-8 and, 10.

[0032] In the modification of FIG. 7, scores 25 and 35 are placed atboth the top and bottom of the panel.

[0033] In the modification of FIG. 9, a pair of diagonal scores 40 and41 are formed in the panel, extending between opposite corners of thepanel and crossing at the middle.

[0034] The scores define weakened lines along which the panel buckles,if buckling occurs. This provides controlled and predictable buckling ofthe panel, with the buckling occurring near an edge rather than in themiddle of the panel, and also generally horizontally rather thanvertically. Buckling of a panel incorporating a score or scores inaccordance with the invention results in less outward bulge than mightoccur with a conventional construction.

[0035] As shown in FIG. 5, reinforcing straps or tapes 50-56 may beincorporated in the corrugated material to strengthen the bin againstradial expansion due to the pressure exerted on the side walls byproduct stored in the bin. In the particular example shown, for a binhaving a height h of 40½ inches, the first tape 50 is spaced two inchesfrom the bottom edge of the wall panels, second tape 51 is spaced twoinches from tape 50, third tape 52 is spaced three inches from tape 51,fourth tape 53 is spaced three inches from tape 52, and the remainingtapes 54, 55 and 56 are spaced eight inches apart, with tape 54 spacedeight inches from the next adjacent tape 53. A greater or lesser numberof tapes may be used, depending upon the requirements, and the tapes maybe spaced differently, or eliminated entirely. Further, the tapes may beapplied externally of the bin, if desired.

[0036] While the bulk bin of the invention has been illustrated anddescribed herein as octagonal in shape, it could have more than eightsides, all sides could be equal in width, or the sides could vary inwidth by about five percent.

[0037] A loaded bulk bin according to the invention bulges significantlyless than conventional bulk bins, and it appears that product stress onthe package is distributed more evenly than in conventional packages,which reduces or eliminates instances of package failure.

[0038] While particular embodiments of the invention have beenillustrated and described in detail herein, it should be understood thatvarious changes and modifications may be made to the invention withoutdeparting from the spirit and intent of the invention as defined by thescope of the appended claims.

What is claimed is:
 1. A bulk bin having side walls joined by diagonalcorner panels to define a polygonal enclosure, wherein the diagonalcorner panels have a width as great as at least some of the side walls.2. In an octagonal bulk bin having opposed parallel side walls spaced apredetermined distance apart, opposed parallel end walls spaced apredetermined distance apart, and diagonal corner panels joining theside and end walls, the improvement comprising: said diagonal cornerpanels having the same width as said end walls, defining side and endwalls of reduced width at said predetermined distance apart, wherebysaid bin fits a predetermined pallet size and said side and end wallsundergo minimum bulge when a flowable product is loaded into the bin. 3.A bulk bin as claimed in claim 2, wherein: the diagonal corner panelsand end walls all have the same width; and said side walls have a widthapproximately fifty percent greater than the width of the end walls andthe diagonal corner panels, resulting in an octagon that is equilateralexcept that it is elongated approximately twenty percent in a directionparallel to the side walls.
 4. A bulk bin as claimed in claim 3,wherein: the bin is formed from corrugated paperboard.
 5. A bulk bin asclaimed in claim 4, wherein: a weakened area is formed in at least oneof said side and end walls to form a line along which said wall willbuckle in a controlled and predetermined manner, if it buckles, from thepressure of material placed in the bin.
 6. A bulk bin as claimed inclaim 5, wherein: the weakened area comprises a scoreline.
 7. A bulk binas claimed in claim 6, wherein: the scoreline forms a generallyparabolic shape converging downwardly from opposite upper corners ofsaid wall and terminating in a curved bight spaced above the midpoint ofthe wall.
 8. A bulk bin as claimed in claim 7, wherein: a furtherscoreline forms a second generally parabolic shape converging upwardlyfrom opposite lower corners of said wall and terminating in a curvedbight spaced below the midpoint of the wall.
 9. A bulk bin as claimed inclaim 5, wherein: the weakened area comprises a pair of diagonalscorelines extending from corner to diagonally opposite corner of saidwall.
 10. A bulk bin as claimed in claim 2, wherein: at least onereinforcing strap extends around said bin to reinforce it against radialexpansion.
 11. A bulk bin as claimed in claim 5, wherein: at least onereinforcing strap extends around said bin to reinforce it against radialexpansion.
 12. In a bulk bin having opposed pairs of parallel side wallsand parallel end walls, the improvement comprising: scorelines in atleast one of said side and end walls to form a line along which saidwall will buckle in a controlled and predetermined manner, if itbuckles, from the pressure of material placed in the bin.
 13. A bulk binas claimed in claim 12, wherein: at least one reinforcing strap extendsaround said bin to reinforce it against radial expansion.
 14. A bulk binas claimed in claim 12, wherein: diagonal corner panels join the sidewalls to the end walls.
 15. A bulk bin as claimed in claim 14, wherein:the diagonal corner panels and end walls are equal in width.
 16. A blankof corrugated paperboard for constructing a polygonal bulk bin,comprising: a plurality of rectangularly shaped panels joined alongparallel fold lines; said panels including first panels having a firstwidth and defining side walls in a bulk bin erected from said blank,second panels having a second width and defining end walls in a bulk binerected from said blank, and third panels interposed between said firstand second panels and having the same width as the second panels anddefining diagonal corner panels in a bulk bin erected from said blank.17. A blank as claimed in claim 16, wherein: there are a pair of firstpanels, which define a pair of opposed side walls spaced a predetermineddistance apart in a bulk bin erected from the blank, and a pair ofsecond panels which define a pair of opposed end walls spaced apredetermined distance apart in a bulk bin erected from the blank; thefirst, second and third panels delineate a certain perimeter in a bulkbin erected from the blank, said certain perimeter being less than theperimeter delineated by corresponding panels in a bulk bin erected froma blank in which the third panels have a width substantially less thanthe width of the second panels; and said predetermined distances betweenthe first and second panels in a bulk bin erected from the blank of theinvention are the same as the distance between corresponding panels in abulk bin erected from a blank in which the third panels have a widthsubstantially less than the width of the second panels.
 18. A blank asclaimed in claim 17, wherein: in a bulk bin erected from the blank ofthe invention and having said predetermined distances between the pairof first panels and the pair of second panels, the width of the firstand second panels is less than the width of corresponding panels in abulk bin erected from a blank in which the width of the third panels isless than the width of the second panels and in which said predetermineddistance is the same.